Capacitive Lubricant Container Sensing for Accurate Auto Lubrication
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Solution Overview
Problem
Existing automatic lubrication systems lack reliable and efficient methods to determine lubrication parameters such as lubricant levels and dispensing accuracy, especially in environments with mechanical influences like vibration and temperature variations, which can lead to inadequate lubrication and reduced equipment lifespan.
Innovation Solution
An automatic lubrication system equipped with a capacitive sensor attached to the lubricant container's wall, which generates sensor signals indicative of capacitance changes due to lubricant levels, allowing the control circuitry to accurately determine and monitor lubrication parameters, including lubricant levels and dispensing accuracy, independent of environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional lubrication systems are used without capacitive sensors, then the system structure remains simple, but the measurement precision of lubrication parameters deteriorates under mechanical influences
Solution Approach 1:
The patent replaces mechanical measurement methods with capacitive sensing technology. The capacitive sensor detects lubrication parameters (such as lubricant level and dispensing amount) through electrical field changes rather than mechanical contact, thereby achieving high measurement precision while being immune to mechanical influences like vibration and temperature variations.
Solution Approach 2:
The capacitive sensor acts as an intermediary between the lubricant container and the control circuitry. It converts physical lubrication parameters into electrical signals that can be processed by the control system, enabling accurate monitoring without direct mechanical interaction between the measurement system and the lubricant.
2Reliability
If capacitive sensors are integrated into the lubricant container wall, then measurement reliability improves under vibration and temperature variations, but device complexity increases
Solution Approach 1:
The patent replaces mechanical measurement systems with capacitive sensing that is inherently immune to mechanical influences. The capacitive sensor mounted on the container wall measures lubrication parameters through electrical field changes, providing reliable measurements even under vibration and temperature variations without requiring complex mechanical isolation systems.
Solution Approach 2:
The capacitive sensor system is mounted directly on the lubricant container wall, utilizing the container structure itself as part of the sensing system. This integration allows the sensor to automatically track lubrication parameters without requiring separate mounting structures or complex installation procedures.
3Productivity
If manual lubrication application is used, then device complexity is low, but productivity and maintenance effort increase
Solution Approach 1:
The patent implements a feedback control system where the capacitive sensor continuously monitors lubrication parameters and provides real-time data to the control circuitry. The control system uses this feedback information to automatically adjust lubrication actions, ensuring optimal lubrication timing and quantity without manual intervention, thereby improving productivity while maintaining manageable system complexity.
Solution Approach 2:
The automatic lubrication system with capacitive sensing enables the lubrication process to be self-regulating. The system automatically determines when and how much lubricant to dispense based on real-time sensor data, eliminating the need for manual monitoring and adjustment, thus improving productivity while the modular design keeps complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides reliable, efficient, and cost-effective monitoring of lubrication parameters, ensuring proper lubrication and extending equipment lifespan by accurately determining lubricant levels and dispensing amounts, even in mechanically challenging environments.
Implementation Method 1
at least one capacitive sensor (also referred to as capacitance sensor and/or sensor hereinafter), which sensor includes at least one electrode, wherein the at least one capacitive sensor is arranged at, mounted at and/or attached to a wall of the lubricant container and configured to provide at least one sensor signal indicative, representative and/or descriptive of a capacitance in a vicinity of the at least one electrode
Data Source
AI summary
An automatic lubrication system for lubricating an object is provided, which includes a lubricant container configured to contain a lubricant and including a rotatable shaft with a piston to dispense the lubricant from an output of the lubricant container, a housing with a coupling section coupled with the lubricant container, an electric motor configured to drive the rotatable shaft of the lubricant container during at least one lubrication action, such that at least a part of the lubricant is dispensable from the lubricant container during the at least one lubrication action, at least one capacitive sensor including at least one electrode, wherein the at least one capacitive sensor is arranged at a wall of the lubricant container and configured to provide at least one sensor signal indicative of a capacitance in a vicinity of the at least one electrode, and a control circuitry configured to determine, based on the at least one sensor signal of the at least one capacitive sensor, at least one lubrication parameter indicative of the at least one lubrication action.